Calibrating Mechanical Pointer Gauge with Electric Sensor
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The existing calibration methods for mechanical pressure gauges are time-consuming, costly, and lack reproducibility due to reliance on human operator experience and iterative trial-and-error processes, often resulting in miscalibration due to hysteresis effects.
Innovation Solution
The method employs an electric sensor to precisely determine the position of a calibration pointer device at multiple calibration values, allowing for automated calculation and adjustment of correction values, reducing the need for human intervention and improving accuracy by considering hysteresis effects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If human operator assessment is used for calibration, then flexibility and adaptability are maintained, but time consumption and lack of reproducibility increase
Solution Approach 1:
The patent replaces the human operator's visual assessment and manual adjustment process with an automated optical measurement system. A camera captures images of the pointer position, and image processing algorithms automatically determine the pointer's angular position. This substitution eliminates the time-consuming manual assessment while maintaining calibration flexibility through programmable measurement parameters.
Solution Approach 2:
The calibration system performs self-assessment by automatically capturing pointer positions, calculating deviations from expected values, and determining correction amounts without human intervention. The system can autonomously iterate through multiple calibration points, making the process reproducible and significantly faster while retaining adaptability through configurable calibration parameters.
2Manufacturing precision
If iterative trial and error method is used for calibration, then accuracy can be improved, but time consumption and cost increase
Solution Approach 1:
The patent implements a feedback mechanism where the optical measurement system continuously monitors pointer positions at multiple calibration points. The system calculates the actual readings versus expected readings, determines correction amounts, and applies corrections systematically. This feedback loop eliminates the need for iterative trial-and-error adjustments by providing direct quantitative information about calibration deviations.
Solution Approach 2:
The system performs preliminary measurements at multiple calibration points (e.g., 0%, 50%, 100% of full scale) before applying any corrections. By pre-assessing all calibration points and calculating the necessary corrections based on the pattern of deviations, the system can apply a single set of corrections that addresses all points simultaneously, rather than iteratively adjusting one point at a time.
3Manufacturing precision
If pointer and dial are removed and reattached for adjustment, then gauge can be corrected, but time and cost efficiency decrease
Solution Approach 1:
The patent replaces the mechanical process of removing and reattaching pointers and dials with an optical measurement and calculation system. The camera-based system can measure pointer positions through the dial face without physical disassembly, and the computational system determines corrections that can be applied while components remain installed. This substitution maintains correction capability while dramatically improving calibration efficiency.
Solution Approach 2:
The patent introduces an optical intermediary (camera imaging system) that allows measurement and assessment of pointer positions without direct physical contact or disassembly. The imaging system acts as an intermediary between the gauge components and the measurement process, enabling corrections to be calculated and applied while the pointer and dial remain in place, thus maintaining productivity.
Data Source
AI summary
The object of the present invention is to provide a solution for calibrating an adjustable mechanical pointer gauge for measuring a physical quantity, for example a pressure gauge, that is more time and cost efficient than previous methods. This object is achieved by a method that comprises determining the positions of a calibration pointer device (11) at at least two different calibration values of the physical quantity and, if necessary, adjusting the gauge (2) based on the determined positions, wherein the positions of the calibration pointer device (11) are determined using an electric sensor (12). A calibration device according to the invention comprises a calibration pointer device (11) configured to replace a measurement pointer device, the calibration pointer device (11) having a plurality of pointer elements (14) which are assigned each to a different one of the calibration values, the calibration device (11) further comprising at least one electrical sensor (12) configured to be mounted to the mechanical gauge (2) at a fixed position and adapted to determine the position of each pointer element (14) at its assigned value.